Lightweighting Aircraft Bracket Design: How Potez Aéronautique Achieved Major Weight Savings
One of the most effective strategies is structural lightweighting—removing unnecessary material while maintaining strength and safety. However, conventional CAD tools often fall short, leading to design limitations, inefficiencies, and costly iterations. Thus, Cognitive Design serves as a powerful enabler, helping to overcome these challenges by unlocking new possibilities in optimization and manufacturability.
In collaboration with Potez Aéronautique, a leading aerostructure supplier, we leveraged Cognitive Design's capabilities to optimize a critical aircraft structural bracket. By integrating topology optimization workflow, Simulation-Driven Design, and Manufacturing-Driven Design within a single environment, we successfully reduced engineering lead time threefold and achieved a 30% weight reduction compared to an optimized bracket for machining.
in this case study, discover how Potez Aéronautique accelerated development, enhanced performance, and minimized manufacturing risks with our cutting-edge design approach.
The optimized part
The outcomes
Performances:
30% compared to optimization for Machining
8% stress reduction after Topology optimization
Engineering lead time reduction:
28 hours (3 times faster than traditional CAD methods)
The workflow in Cognitive Design
- Topology optimization workflow
- Simulation-Driven Design
- Manufacturing-Driven Design
- Back to CAD
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Design Smarter with Data-Driven Decision Making
Cognitive Design brings full visibility to your design process with smart AI-driven reports. This capability allows you to link key design and business metrics across every iteration.
Automate design generation to achieve maximum performance in no time.
Instant comparison of cost, weight, CO₂ and lead time
Seamless report generation for technical reviews and stakeholders
Built for the Cognitive Era of Engineering
Shorten product development cycle from the earliest concept phase.
Product engineering cycle
Product engineering cycle
Reusability of engineering workflows
FAQs
Explore our frequently asked questions to understand how our software can benefit you.
Yes, some functions in cognitive design uses AI (costing, conversion to CAD, manufacturing analysis). It is pre-trained by CDS and packaged in the software, so there is no training happening on your side, and your data is not used.
Yes, you can convert mesh or implicit models to CAD and export them as a .step. It works best for midly complex models (e.g. generative design results). Lattice models could techically be converted to CAD, but would be too heavy for CAD tools to import and handle.
No, our APP workflows use hybrid meshing, keep ing the original CAD precision around functional regions, and having smooth mesh elements on organic features.
Cognitive Design uses a proprietary hybrid geometrical engine, mainly based on volumetric modeling (Signed Distance functions), with in addition mesh and CAD operators.
Cognitive Design uses a node-locked license system, tied to each workstation. This approach aligns with the offline, on-premise setup. Floating licenses are not yet available.
You can export 3D models in BREP format, with .step or .stp extensions—ensuring compatibility with most CAD software.
Cognitive Design runs fully offline. It's an on-premise software that doesn’t require any internet connection for day-to-day use.
Cognitive Design is particularly well suited for complex, high-value mechanical parts such as lightweight structures, gearbox housings, functional brackets, or fixtures subjected to multiphysics loads. It is optimized for use cases in aerospace, defense, space, and advanced mobility systems.
Cognitive Design is an advanced design optimization software that enhances part performance. It incorporates production constraints directly into the design phase, ensuring efficiency. This allows design engineers to streamline workflows and reduce development time.
Cognitive Design is tailored for design engineers in large and medium-sized industrial companies. It is particularly beneficial for sectors like aerospace, automotive, defense, and space. The software addresses the unique challenges faced in these industries.
The software uses an implicit modeling engine to generate and optimize designs rapidly. By factoring in manufacturing constraints, it ensures that designs are feasible and efficient. This process minimizes the risk of failure during production.
Cognitive Design significantly reduces development time and enhances agility in the design process. It allows for quick iterations and optimizations, keeping your projects on track. By integrating manufacturing constraints early, it helps maintain competitiveness.
While Cognitive Design is user-friendly, we offer comprehensive training to maximize its potential. Our support team is available to assist with onboarding and any questions. This ensures that users can leverage the software effectively.
Unlock Your Design Potential
Request a demo to see how Cognitive Design by CDS can revolutionize your engineering workflow